Carbon microparticle having lignin as raw material and preparation method therefor

ABSTRACT

The present invention provides a method for preparing a carbon microparticle from an organic raw material having lignin as a main constituent, and a carbon microparticle obtained thereby. 
     An aqueous solution with 5% total concentration of lignin and sodium hydroxide (the proportion in mass is 1:0.5) is spray-dried to prepare a complex microparticle. This is heat-processed under nitrogen atmosphere at 600° C. for one hour and let to cool. Thereafter, this is washed with water and further dried to prepare a hollow carbon microparticle such as those shown in FIG.  2  ( b ). The prepared carbon microparticle is light-weight and has an equivalent specific surface area to commercially available activated charcoal.

TECHNICAL FIELD

The present invention relates to a method for preparing a carbonmicroparticle. More particularly, it relates to a method for preparing acarbon microparticle from various organic raw materials having lignin asmain constituent, and to carbon microparticles obtained thereby.

BACKGROUND ART

In recent years, as global warming and soaring of oil price have becomeproblems at a global scale, transition from fossil resources tobiological resources is being hurried. Meanwhile, on the order of10,000,000 tons per year of prior art carbon microparticles, of whichcarbon black is a representative, are manufactured globally as tirereinforcing agents or the like, and these are conventionallymanufactured by thermal decomposition of fossil resources such as oiland such at high temperatures of on the order of 1400° C.

Here, thermal decomposition of a spherical organic macromoleculecontaining lignin as shown in Patent Reference 1, grinding of athermosetting resin carbon as shown in Patent Reference 2, thermaldecomposition of a thermoplastic resin microparticles having activatedcharcoal powder attached on the surface as shown in Patent Reference 3,deposition of non-graphite structure hollow micro-carbon vaporized bythermal plasma as shown in Patent Reference 4, carbonization ofmicroparticular thermosetting resin prepared by suspensionpolymerization as shown in Patent Reference 5, grinding of a carbonmaterial in a solvent as shown in Patent Reference 6, laser illuminationof a hydrocarbon compound particle as shown in Patent Reference 7, heattreatment of specially shaped carbon black at 2000° C. or higher asshown in Patent Reference 8, thermal decomposition of a synthetic resinby arc-discharge as shown in Patent Reference 9, spray pyrolysis ofcarbohydrates from biomass acid decomposition products as shown inPatent Reference 10, preparation by a piezo-vibrating nebulizergranulating apparatus with a thermosetting resin as a raw material asshown in Patent Reference 11, and the like, exist as other preparationmethods for carbon microparticles. Furthermore, Non-Patent References 1to 4 are reported as scientific articles related to hollow carbonmicroparticles.

[Patent Reference 1] Japanese Patent Application Laid-open No.H01-207719[Patent Reference 2] Japanese Patent Application Laid-open No.H03-164416[Patent Reference 3] Japanese Patent Application Laid-open No.H07-187849[Patent Reference 4] Japanese Patent Application Laid-open No.H07-267618

[Patent Reference 5] Japanese Patent Application Laid-open No.2001-220114 [Patent Reference 6] Japanese Patent Application Laid-openNo. 2002-241116 [Patent Reference 7] Japanese Patent ApplicationLaid-open No. 2004-526652 [Patent Reference 8] Japanese PatentApplication Laid-open No. 2005-281065 [Patent Reference 9] JapanesePatent Application Laid-open No. 2005-53745 [Patent Reference 10]Japanese Patent Application Laid-open No. 2005-289666 [Patent Reference11] Japanese Patent Application Laid-open No. 2006-75708 [Non-patentReference 1] Journal of Colloid and Interface Science, Vol. 177, 325-328(1996) [Non-patent Reference 2] Advanced Materials, Vol. 14, 1390-1393(2002) [Non-patent Reference 3] Chemistry of Materials, Vol. 15,2109-2111 (2003) [Non-patent Reference 4] Microporous and MesoporousMaterials, Vol. 63, 1-9 (2003)

However, no preparation technique for carbon microparticle has beenestablished from raw materials having lignin as a main constituent. InPatent Reference 1, lignin is cited as no more than an example of rawmaterials for a spacer between facing substrates in a liquid crystaldisplay device, and in order to conform to this application, it sufficesthat the microparticles are spherical and the particle diameter is onthe order of few μm to tens of μm. However, in cases such as when themicroparticles are used as filling materials, adsorption materials andthe like, the characteristics of the microparticles needed depending onthe application are different. In particular, many cases require lightweight, high strength, high specific surface area and the like, and theestablishment of a technique for preparing a carbon microparticleprovided with the desired characteristics is much expected in thepresent technical field. As lignin is present in large quantities innature, particularly in wood, if preparing carbon microparticles becomespossible from raw materials containing lignin, it will result in a largecontribution in the transition from fossil resources to biologicalresources. Moreover, biomasses containing lignin such as pulp wasteliquid and waste wood, which are discarded from pulp manufacturingprocesses, and waste from agricultural products, are discarded in largeamounts, with their treatment requiring large costs and being alsotechnically difficult.

DISCLOSURE OF THE INVENTION

The present invention was devised in view of such issues, and an objectthereof is to provide a method for preparing a carbon microparticle froman organic raw material having lignin as a main constituent, and inparticular, to provide a preparation method for a carbon microparticlehaving high strength, light weight and high specific surface area. It isanother object of the present invention to provide a method forpreparing a carbon microparticle from organic raw materials havinglignin as a main constituent which saves energy.

In order to solve the above issues, the present invention adopts thefollowing means.

The carbon microparticle preparation method according to the presentinvention 1 is characterized in that a solution of organic raw materialhaving lignin as a main constituent is turned into a micro-droplet, themicro-droplet is dried to prepare a microparticle, and the microparticleis thermally decomposed in a range of 300° C. to 1200° C. to prepare acarbon microparticle.

The carbon microparticle preparation method according to the presentinvention 2 is characterized in that a mixed solution of an organic rawmaterial having lignin as a main constituent and an inorganic substanceis turned into a micro-droplet, the micro-droplet is dried to prepare amicroparticle, and the microparticle is thermally decomposed in a rangeof 300° C. to 1200° C. to prepare a carbon microparticle.

The carbon microparticle preparation method according to the presentinvention 3 is characterized in that, in the carbon microparticlepreparation method described in the present invention 2, the inorganicsubstance is a metal compound constituted by one or more speciesselected from the group consisting of an oxide, a hydroxide, a carbonateand a halide of a metal, and, based on the property that a carbon wallthickness of the carbon microparticle (portion of the shell that forms ahollow carbon microparticle) becomes thinner as the proportion of themetal compound added increases, the proportion of the metal compoundadded is adjusted to control the carbon wall thickness of themicroparticle.

The carbon microparticle preparation method according to the presentinvention 4 is characterized in that, in the carbon microparticlepreparation method described in the present invention 2, prior to beingtaken out into the air, the carbon microparticle obtained during thethermal decomposition or after the thermal decomposition is brought intocontact beforehand with a gas having low reactivity, therebyinactivating the surface of the carbon microparticle by reaction withthe gas and inhibiting a rapid heat generation occurring when the carbonmicroparticle is taken out into the air.

The carbon microparticle preparation method according to the presentinvention 5 is characterized in that a mixed solution of organic rawmaterials having lignin as a main constituent and a basic compound isturned into a micro-droplet, the micro-droplet is dried to prepare amicroparticle, and the microparticle is thermally decomposed in a rangeof 300° C. to 1200° C. and the specific surface area is increased toprepare a carbon microparticle. This specific surface area isapproximately 900 m²/g or greater.

The carbon microparticle preparation method according to the presentinvention 6 is characterized in that preprocessing to raise theconstituent ratio of lignin is carried out on a pulp waste solution, thepulp waste solution after the preprocessing is turned into amicro-droplet, the micro-droplet is dried to prepare a microparticle,and the microparticle is thermally decomposed in a range of 300° C. to1200° C. to prepare a carbon microparticle.

The carbon microparticle preparation method according to the presentinvention 7 is characterized in that preprocessing to raise theconstituent ratio of lignin is carried out on a pulp waste solution, asolution comprising the pulp waste solution after the preprocessingadded with an inorganic substance is turned into a micro-droplet, themicro-droplet is dried to prepare a microparticle, and the microparticleis thermally decomposed in a range of 300° C. to 1200° C. to prepare acarbon microparticle.

The carbon microparticle preparation method according to the presentinvention 8 is the carbon microparticle preparation method described inthe present invention 6 or 7, characterized in thatseparation-collection of high molecular weight lignin is carried out byultrafiltration as the preprocessing.

The carbon microparticle preparation method according to the presentinvention 9 is the carbon microparticle preparation method described inthe present invention 6 or 7, characterized in that a process is carriedout as the preprocessing, in which carbon dioxide is absorbed by thepulp waste solution to thereby decrease a hydrogen ion index and deposita portion of an organic constituent, and the organic constituent isseparated.

The carbon microparticle according to the present invention 10 is ahollow carbon microparticle characterized in that it is obtained byturning a solution of lignin, or lignin and an inorganic substance intoa micro-droplet, drying the micro-droplet is to prepare a microparticle,and thermally decomposing the microparticle in a range of 300° C. to1200° C.

The carbon microparticle according to the present invention 11 is ahollow carbon microcell, characterized in that it is obtained by turninga solution of lignin, or lignin and a basic compound into amicro-droplet, drying the micro-droplet to prepare a microparticle, andthermally decomposing the microparticle in a range of 300° C. to 1200°C., and in that it has an external diameter of 0.2 to 50 μm and a carbonwall thickness of 0.05 to 20 μm.

The carbon microparticle according to the present invention 12 is thehollow carbon microcell described in the present invention 11,characterized in that the proportion in mass of the lignin and the basiccompound is 1:0.5 to 1:2, and the carbon microparticle is hollow and hasa high specific surface area. From the fact that the carbon wall becomesthin when the proportion in mass of the basic compound is larger, thecarbon wall thickness can be controlled by adjusting the proportion inmass thereof within the range given above. Then, the specific surfacearea increases remarkably along with increasing proportion in mass ofthe basic compound. However, when the basic compound was added with aproportion that exceeded 1:2, melting of microparticles was triggered.

The carbon microparticle according to the present invention 13 is ahollow carbon microballoon characterized in that it is obtained byturning a solution of lignin as well as a metal compound constituted byone or more species selected from the group consisting of an oxide, ahydroxide, a carbonate and a halide of a metal into a micro-droplet,drying the micro-droplet to prepare a microparticle, and thermallydecomposing the microparticle in a range of 300° C. to 1200° C., and inthat it has an external diameter of 0.2 to 50 μm, a carbon wallthickness of 5 to 200 nm and a bulk density of 3 to 20 g/L.

The carbon microparticle according to the present invention 14 is thecarbon microballoon described in the present invention 13, characterizedin that the proportion in mass of the lignin and the metal compound is1:3 to 1:20. From the fact that the carbon wall becomes thin when theproportion in mass of the metal compound is larger, the carbon wallthickness can be controlled by adjusting the proportion in mass thereofwithin the range given above. However, when the metal compound was addedwith a proportion of less than 1:3, no carbon microballoon wasgenerated, and when added with a proportion exceeding 1:20, themicroballoons broke up without becoming hollow, and only aggregatedproducts could be obtained.

The carbon microparticle according to the present invention 15 is ahollow carbon nanopipe cell characterized in that it is a hollow carbonmicroparticle obtained by turning a solution of lignin and metasilicateinto a micro-droplet, drying the micro-droplet to prepare amicroparticle, and thermally decomposing the microparticle in a range of300° C. to 1200° C., and in that it has an external diameter of 0.2 to50 μm and a carbon wall thickness of 0.05 to 20 μm, and furthermore, thecarbon wall thereof is constituted by a carbon nanopipe having anexternal diameter of 5 to 50 nm and a carbon wall thickness of 1 to 5nm.

The carbon microparticle according to the present invention 16 is thecarbon nanopipe cell described in the present invention 15,characterized in that the proportion in mass of the lignin and themetasilicate is 1:3 to 1:20. From the fact that the carbon wall becomesthin when the proportion in mass of metasilicate is increased, thecarbon wall thickness can be controlled by adjusting the proportion inmass thereof within the range given above. However, when metasilicatewas added with a proportion of less than 1:3 or exceeding 1:20, nocarbon nanopipe cell was generated.

The carbon microparticle according to the present invention 17 is ahollow, non-graphite carbon nanocell, characterized in that it isobtained by turning a solution of lignin and orthosilicate into amicro-droplet, drying the micro-droplet to prepare a microparticle, andthermally decomposing the microparticle in a range of 300° C. to 1200°C., and in that it has an external diameter of 3 to 30 nm, a carbon wallthickness of 1 to 5 nm and a specific surface area of 1400 to 1600 m²/g.

The carbon microparticle according to the present invention 18 is thecarbon nanocell described in the present invention 17, characterized inthat the proportion in mass of the lignin and the orthosilicate is 1:5to 1:20. From the fact that the carbon wall becomes thin when theproportion in mass of orthosilicate is increased, the carbon wallthickness can be controlled by adjusting the proportion in mass thereofwithin the range given above. However, when orthosilicate was added witha proportion of less than 1:5 or exceeding 1:20, no carbon nanocell wasgenerated.

Hereafter, each element constituting the present invention will bedescribed concretely.

[Organic Raw Materials]

As referred to in the present invention, organic raw materials havinglignin as a main constituent include, in addition to lignin, organiccompounds in waste solutions discarded in the manufacturing process ofpaper pulp or waste solutions from the preprocessing thereof, andfurther, those from the preprocessing of plant raw materials containinglignin such as wood and plants. Lignin is, for instance, a highmolecular weight aromatic polymer compound present for instance in woodat 20 to 30 mass %, constituting the intermediate layer between a cellmembranes, a portion being considered to be present in a cell membrane.A variety of methods are known for separating lignin from a plant body,and these methods are used. Concretely, lignin as referred to in thepresent invention means alkaline lignin, hydrolyzed lignin, ligninsulfonic acid and the like.

[Preprocessing]

As referred to in the present invention, preprocessing refers to aprocess for raising the constituent ratio of lignin from [that in] anorganic raw material containing lignin, or a process for improvinglignin into a structure suitable for the preparation of carbonmicroparticles. That is to say, it is a process prior to turning anorganic raw material containing lignin into a micro-droplet. Forinstance, when a pulp waste solution is used as an organic raw material,although it is not necessarily a mandatory process, it is desirable toperform preprocessing for raising the constituent proportion of lignin.Concretely, processes such as (1) absorption of acidic gas toprecipitate and separate lignin; (2) addition of an inorganic acid, amultivalent cation or an organic amine to precipitate and separatelignin; (3) fermentation and removal by degradation of sugars in thepulp waste solution; and (4) separation and collection of high molecularweight lignin by ultrafiltration can be considered. Filtration is ageneral method for separating water and lignin with a filter. Theultrafiltration membranes used in the present invention refer to porousmembranes with pore diameters ranging from 1 nm to 100 nm (0.1 μm).

In addition, for preprocessing when using wood, plants and the like asorganic raw materials, for instance, well known methods such as alkalinedecomposition used in pulp manufacturing or the like can be used. Inaddition, the constituent ratio of lignin can be raised by using thelignin separation-concentration method described above, or the like, asnecessary.

[Thermal Decomposition]

As referred to in the present invention, thermal decomposition refers toheating and carbonizing an organic raw materials containing lignin at300° C. to 1200° C. In general, thermal decomposition is performed at500° C. to 800° C.

[Inorganic Substance]

The inorganic substances used in the present invention are used tocontrol various characteristics such as carbon wall thickness of carbonmicroparticle, thermoplasticity of lignin, pore structure of carbon walland conductivity of carbon microparticle. As referred to in the presentinvention, inorganic substances include, in addition to single bodycarbons, water soluble salts such as an oxide, a hydroxide, a carbonate,a halide, a sulfate, a nitrate, a silicate, a phosphate and a borate ofa metal, as well as these microparticles thereof and micro-fibersthereof.

[Inactivation]

As referred to in the present invention, inactivation refers to bringinga carbon microparticle obtained during thermal decomposition or afterthermal decomposition into contact with a gas having low reactivity toinactivate the surface of the carbon microparticle. This inactivationallows the rapid heat generation occurring when the carbon microparticleis taken out to be suppressed. Gas with low reactivity means water vaporgas, nitrogen gas containing low concentration of oxygen, and the like.Then, since generation of a gentle reaction with the carbonmicroparticle surface is required, totally inactive gas such as purenitrogen is not applicable.

[Turning into Micro-Droplet]

As referred to in the present invention, turning into a micro-dropletrefers to turning for instance a pulp waste solution after preprocessinginto micro-droplets with diameters on the order of few tens of μm orless by methods such as spraying and ultrasonic nebulization.

[Carbon Microparticle]

As referred to in the present invention, a carbon microparticle refersto a particle comprising thermally decomposed or carbonized lignin inthe organic compound. Carbon microparticles have various sizes(diameters on the order of few nm to 50 μm) and morphologies. Inaddition, it is characterized by a bulk density of 3 to 300 g/L, and alight weight.

According to the carbon microparticle preparation method of the presentinvention, carbon microparticles can be prepared from a solution oforganic raw materials having lignin as a main constituent, which is aregenerable biological resource. This contributes greatly in thetransition from fossil resources to biological resources for preparingcarbon microparticles. In addition, various characteristics of thecarbon microparticle such as carbon wall thickness can be controlledsimply by adjusting the proportions of the added inorganic substances.Furthermore, by bringing the carbon microparticle obtained by thermaldecomposition into contact with a gas having low reactivity, the rapidheat generation occurring when [the particle is] taken out into the aircan be suppressed.

The carbon microparticle preparation method of the present inventionallows a carbon microparticle to be prepared also from a mixed solutionof organic raw materials having lignin as a main constituent and a basiccompound, and a carbon microparticle obtained thereby is suited to avariety of applications as the specific surface area is equivalent tocommercially available activated charcoal. From the fact that it ishollow, the carbon microparticle obtained by the preparation method ofthe present invention has the property of being extremely light involume ratio compared to a conventional carbon microparticle, which isfilled with carbon or the like all the way inside. Consequently, it issuited in particular to applications that require light weight. Thecarbon microparticle preparation method of the present invention allowscarbon microparticles to be prepared also from pulp waste solutions, andpulp waste solutions can be used actively as biomass resources toprepare carbon microparticles. Furthermore, since the carbonmicroparticle preparation method of the present invention allows carbonmicroparticles to be prepared at lower heat treatment temperature thanprior art, it also contributes to energy saving.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 (a) is a photograph of hollow carbon microparticles prepared fromlignin sulfonic acid only, and FIG. 1 (b) is a magnified photograph of afracture cross section of a hollow carbon microparticle thereof;

FIG. 2 (a) is a magnified photograph of a fracture cross section of acarbon microparticle when the proportion in mass of lignin and sodiumhydroxide is 1:0.25, FIG. 2 (b) is a magnified photograph of a fracturecross section of a carbon microparticle when the proportion in mass oflignin and sodium hydroxide is 1:0.5, and FIG. 2 (c) is a magnifiedphotograph of a fracture cross section of a carbon microparticle whenthe proportion in mass of lignin and sodium hydroxide is 1:1;

FIG. 3 (a) is a photograph of hollow carbon microparticles prepared fromlignin, sodium hydroxide and sodium chloride (proportion inmass=1:0.25:3), and FIG. 3 (b) magnified photograph of the fracturecross section of a hollow carbon microparticle thereof;

FIG. 4 (a) is a low magnification photograph of carbon nanoparticlesprepared from lignin, sodium hydroxide and sodium metasilicate(proportion in mass=1:0.25:10), and FIG. 4 (b) is a high magnificationphotograph of a carbon nanoparticle thereof;

FIG. 5 (a) is a photograph of carbon prepared from a pulp waste solutionwhich has not been preprocessed, FIG. 5 (b) is a photograph of carbonmicroparticles when ultrafiltration processing was performed on a pulpwaste solution and high molecular weight constituents served as rawmaterials, and FIG. 5 (c) is a magnified photograph of a fracture crosssection of a carbon microparticle thereof;

FIG. 6 (a) is a photograph of carbon microcells prepared by ultrasonicnebulization and FIG. 6 (b) is a magnified photograph of a carbon wallportion in the fracture cross section of a carbon microcell thereof;

FIG. 7 is a photograph of carbon microballoons;

FIG. 8 (a) is a photograph of a carbon nanopipe cell and FIG. 8 (b) is amagnified photograph of a carbon wall portion in the fracture crosssection of a carbon nanopipe cell thereof; and

FIG. 9 is a photograph of carbon nanocells.

BEST MODE FOR CARRYING OUT THE INVENTION

In the present invention, first, an organic raw material having ligninas a main constituent, which is a biological resource, or a solution ofa mixture of this organic raw material and an inorganic substance isturned into a micro-droplet and dried to prepare an organic compoundmicroparticle or a complex microparticle of an organic raw material andan inorganic substance. This organic compound microparticle or complexmicroparticle is thermally decomposed in a range of 300° C. to 1200° C.and left to cool to prepare a carbon microparticle. Here, if thereactivity of the product after thermal decomposition is high, theproduct is inactivated by being brought into contact with a gas having alow reactivity. In addition, if necessary, the product is washed withwater or the like to remove inorganic substances and then dried. Thecarbon microparticles prepared in this way have a variety of sizes(diameters on the order of few nm to 50 μm) and morphologies. Inaddition, they are characterized by bulk densities of 3 to 300 g/L and alight weight.

In the following, the light weight carbon microparticle preparationmethod according to the present invention will be described usingfigures.

Example 1

An aqueous solution with 5% total concentration of lignin sulfonic acidwas spray-dried to prepare microparticles of lignin sulfonic acid. Thiswas heat-processed under nitrogen atmosphere at 600° C. for one hour andlet to cool to prepare hollow carbon microparticles such as those shownin FIGS. 1 (a) and (b). The hollow carbon microparticles had diameterson the order of few μm to 10 μm.

Example 2

An aqueous solution with 5% total concentration of lignin and sodiumhydroxide (proportion in mass was 1:0.25) was spray-dried to preparecomplex microparticles. This was heat-processed under nitrogenatmosphere at 600° C. for one hour and let to cool. Thereafter, this waswashed with water and further dried to prepare hollow carbonmicroparticles such as those shown in FIG. 2 (a). In addition, a similarprocess was performed on an aqueous solution with 1:0.5 as theproportion in mass of lignin and sodium hydroxide and 5% totalconcentration to prepare hollow carbon microparticles such as thoseshown in FIG. 2 (b). In addition, setting the proportion in mass oflignin and sodium hydroxide to 1:1, a similar process was performed onan aqueous solution with a total concentration of 5% to prepare hollowcarbon microparticles such as those shown in FIG. 2 (c). The diametersof the hollow carbon microparticles in each of FIGS. 2 (a) to (c) wereall on the order of few μm.

From FIGS. 2 (a) to (c) it is possible to appreciate that when theproportion in mass of lignin and sodium hydroxide varies, the carbonwall thickness of the hollow carbon microparticle varies concomitantly.Concretely, the carbon wall thickness of the hollow carbon microparticletended to be thin along with increasing amounts of sodium hydroxideadded. That is to say, this result shows that the carbon wall thicknessof the hollow carbon microparticle can be controlled by adjusting theproportion of sodium hydroxide added.

Example 3

An aqueous solution with 5% total concentration of lignin, sodiumhydroxide and sodium chloride (proportion in mass was 1:0.25:3) wasspray-dried to prepare complex microparticles. This was heat-processedunder nitrogen atmosphere at 600° C. for one hour and let to cool.Thereafter, this was washed with water and further dried to preparehollow carbon microparticles such as those shown in FIG. 3. The diameterof this hollow carbon microparticle was on the order of few μm to 20 μm.In addition, the bulk density was approximately 30 g/L, which wasextremely light.

Example 4

An aqueous solution with 5% total concentration of lignin, sodiumhydroxide and sodium metasilicate (proportion in mass was 1:0.25:10) wasspray-dried to prepare complex microparticles. This was heat-processedunder nitrogen atmosphere at 600° C. for one hour and let to cool.Thereafter, this was washed with water and further dried to preparecarbon nanoparticles which diameters were few nm to few tens of nm, suchas those shown in FIG. 4.

Example 5

An aqueous solution with 5% total concentration of lignin, sodiumhydroxide, and graphite (proportion in mass was 1:0.5:0.15) wasspray-dried to prepare complex microparticles. This was heat-processedunder nitrogen atmosphere at 600° C. for one hour and let to cool.Thereafter, this was washed with water and further dried to verify thatsimilar hollow carbon microparticles to FIG. 2 shown in Example 2 wereprepared.

Note that regarding the Examples 2 to 5, in all cases of lignin samples,respectively, alkaline lignin, hydrolyzed lignin and lignin sulfonicacid, it could be verified that almost identical carbon microparticlescould be prepared.

Example 6

Although large amounts of lignin are contained in a pulp waste solutiongenerated when wood chips are processed in a pulp plant, currently,lignin from most of it is incinerated. If carbon microparticles could beprepared from this pulp waste solution, it would be a major contributionto the transition from fossil resources to biological resources andefficient utilization of resources.

However, there are many methods for preparing pulp, and the compositionof each pulp waste solution generated in so doing is also different.When there are large amounts of lignin constituents in a pulp wastesolution, it is possible to prepare carbon microparticles withoutperforming preprocessing such as constituent separation; however, if alarge amount of a constituent other than lignin is contained,preprocessing becomes necessary.

An actual pulp waste solution (total concentration: 23%) was simplydiluted to prepare an aqueous solution with 5% total concentration. Thisaqueous solution was spray-dried to prepare microparticles. This washeat-processed under nitrogen atmosphere at 600° C. for one hour and letto cool, then, washed with water and further dried; the result was thatthe particles were fused to one another and no carbon microparticlecould be obtained as shown in FIG. 5 (a). This is due to heat-melting ofcarbohydrate decomposition products or the like contained in the pulpwaste solution in addition to lignin.

In order to prevent such melting, it is necessary to raise theconstituent ratio of lignin. As methods therefor, a.precipitation-separation of lignin by absorption of acidic gas, b.precipitation-separation of lignin by addition of an inorganic acid, amultivalent cation, or an organic amine, c. decomposition-elimination byfermentation of sugar in pulp waste solution, d. separation-collectionof high molecular weight lignin by ultrafiltration, and the like may beconsidered. It is believed that the constituent ratio of lignin can beraised by any methods.

In the present experiment, as one method with small environmentalburden, d. separation-collection of high molecular weight lignin byultrafiltration was performed, to examine the effect of ultrafiltration.Ten-fold diluted actual pulp waste solution was concentrated ten-foldusing an ultrafiltration membrane with a cut-off molecular weight of10,000. Then, the concentrated solution with a high molecular weightconstituent as raw material was spray-dried to prepare microparticles.This was heat-processed under nitrogen atmosphere at 600° C. for onehour and let to cool, then washed with water, and dried further; theresult was that hollow carbon microparticles such as those shown inFIGS. 5 (b) and (c) could be prepared. The diameter of this hollowcarbon microparticle was on the order of few μm to 10 μm. From this, itwas demonstrated that by raising the constituent ratio of lignin, carbonmicroparticles could be prepared also from raw materials containingvarious organic compounds and inorganic substances other than lignin,such as a pulp waste solution.

In addition, as a promising lignin separation method other thanultrafiltration, separation by absorption of carbon dioxide contained inthe flue gas of paper manufacturing plants can be considered. In theexperimental, as simulated flue gas, a nitrogen gas containing 20%carbon dioxide was flown into a pulp waste solution (pH 13.2) containing12% solid content to lower the pH to 9.5, causing a portion of theorganic constituent to precipitate. This precipitate was separated fromthe solution by centrifugal separation, washed and then dried. Anaqueous solution comprising sodium metasilicate added with a proportionof 1:10 in mass ratio to this dry precipitate (5% total concentration)was spray-dried. This was heat-processed under nitrogen atmosphere at600° C. for one hour and let to cool, then washed with water and furtherdried; the result was that a light-weight hollow carbon microparticle(carbon nanopipe cell described below) was obtained. From this, it wasverified that a carbon microparticle could also be prepared using aconstituent that precipitates by absorbing carbon dioxide gas to thepulp waste solution.

Example 7

As in the case of Example 2, an aqueous solution of lignin and alkalihydroxide or an aqueous solution of lignin and alkali carboxylate wasspray-dried, to prepare a complex microparticle having a diameter on theorder of few microns. This was heat-processed under nitrogen atmosphereat 600° C., let to cool to room temperature, then, when the productcontaining the generated carbon microparticles was taken out into theair, a phenomenon of strong heat generation was observed. Then, suchheat generation was pronounced in the case where, lignin sulfonic acidwas the raw material. The cause of the heat generation is due to thecarbon microparticles and alkaline metals generated by the heattreatment react violently with oxygen or the like in the air.

Here, before the product was taken out into the air, by bringing it intocontact with a gas having comparatively low reactivity such as nitrogengas saturated with moisture, inactivation of the carbon microparticlesurface was possible, and the rapid heat generation occurring when takenout into the air could be controlled.

[Specific Surface Area of Carbon Microparticle]

It was verified that the specific surface area (surface area per unitmass) of a carbon microparticle when lignin alone was heat-processed at600° C. as in the case shown in Example 1, was on the order of 180 to430 m²/g. Meanwhile, it was found that the specific surface areas of thecarbon microparticles in Example 2 (when the proportion in mass oflignin and sodium hydroxide was 1:0.5), 3 and 4 were respectively, 860m²/g, 1280 m²/g and 900 m²/g, as shown in Table 1, and that all wereequivalent to the specific surface area 910 m²/g of commerciallyavailable activated charcoal. From this, carbon microparticles preparedby adding a basic compound such as sodium hydroxide to lignin can alsobe considered as activated charcoal microparticles, and are suited tovarious applications.

TABLE 1 Surface area and pore capacity of carbon particles from theexamples Surface area Micropore Mesopore (m²g⁻¹) (cm³g⁻¹) (cm³g⁻¹)Example 1 300 0.13 0.02 Example 2b 860 0.37 0.16 Example 3 1280 0.451.30 Example 4 900 0.23 1.46 Example 6bc 540 0.24 0.03 Commercially 9100.39 0.05 available activated charcoal

In the present invention, an organic compound microparticle or a complexmicroparticle of organic raw materials and inorganic substance isprepared by turning into micro-droplets and drying a solution of organicraw materials having lignin as a main constituent, which is a biologicalresource, as in Example 1, or a solution of a mixture of organic rawmaterials having lignin as a main constituent and an inorganicsubstance, as in Examples 2 to 7. Regarding this “solution”, in additionto aqueous solutions, organic solutions containing an organic compoundother than lignin, and furthermore, a suspension are included. Inaddition, as “inorganic substance”, as indicated in Examples 3 to 5,mixtures of inorganic substances are included. Here, spray-drying iscarried out in the examples as means for turning [a solution] intomicro-droplets; however, without limiting to this, other means may beused, such as ultrasonic nebulization, as indicated in Example 8described below.

In addition, carbon microparticles are prepared in the present inventionby thermally decomposing organic compound microparticles or complexmicroparticles in a range of 300° C. to 1200° C. and letting to cool.Although the heat processing temperature was 600° C. in the examples,heat processing temperature in the present invention may be in the rangeof 300° C. to 1200° C. Here, drying of the micro-droplets describedabove and thermal decomposition of microparticles may be carried outsimultaneously inside the same reactor. In addition, when the reactivityof the product is high, the product is inactivated by being in contactwith a “gas having low reactivity”; this gas is not limited to nitrogengas pre-saturated with moisture as in Example 7, and may be an inert gasor the like with similarly adjusted moisture. This inactivationprocessing of the product may be carried out as necessary. In addition,washing and drying of the product after thermal decomposition may becarried out as necessary as well.

In prior art, carbon microparticles have been prepared with fossilresources such as oil as raw materials, at high temperatures of 1400° C.or higher. However, with the preparation method of the presentinvention, the fossil resource can be substituted with a biologicalresource such as a pulp waste solution containing lignin. In addition,since the preparation temperature is on the order of 300° C. to 1200° C.and can be lowered significantly compared to prior art technique, thereis contribution to energy saving. In the future, as it is anticipatedthat, along with the promotion of the development of bio-ethanol,inexpensive lignin will be generated in large amounts, the presentinvention is expected to contribute to a decrease in costs and energysaving also from such a context.

Currently, carbon microparticles, of which carbon black is arepresentative, are used in majority as tire reinforcing agent. Thecarbon microparticle generated by the preparation method of the presentinvention is light weight, and some also exist with an equivalentspecific surface area to commercially available activated charcoal, suchthat, in addition to utilization as rubber reinforcing agent such as fortires, utilization is anticipated as activated charcoal, controlledrelease material, black pigment, toner, color filter, conductivematerial, electrostatic prevention agent, battery electrode material,viscous fluid and the like.

Other Examples

Carbon microparticles suited to specific applications (respectivelyreferred to as “carbon microcell”, “carbon microballoon”, “carbonnanopipe cell” and “carbon nanocell”) were prepared by the preparationmethods of Example 8 to 11 shown in the following.

Example 8 Carbon Microcell

An aqueous solution with 5% total concentration of lignin sulfonic acidand sodium hydroxide (proportion in mass was 1:0.1) was ultrasonicallynebulized and heated at 90° C. and dried to prepare ligninmicroparticles. This was heat-processed under nitrogen atmosphere at600° C. for one hour and let to cool. Thereafter, this was washed withwater and further dried to adjust carbon microcells such as those shownin FIG. 6 (a). The diameters of the microparticles shown in this figurewere on the order of 0.2 to 3 μm. FIG. 6 (b) shows a portion of thefracture cross section of a microparticle thereof. It is clear with thisphotograph that these are hollow microparticles with a compact carbonstructure and a carbon wall thickness of approximately 0.3 μm.

Since the carbon microcells prepared in this way have external diametersof 0.2 to 50 μm, carbon wall thicknesses of 0.05 to 20 μm, and a carbonwall with a compact structure, they are high strength, light weighthollow carbon materials. In contrast to prior art hollow carbon havingnumerous mesopores and macropores that provoke a decrease in strength,the carbon microcell of the present invention has a pore structure,which is a compact structure as shown in FIG. 6 (b) with micropores asthe main body, thus has the characteristic of high physical strength.

The carbon microcell obtained in the present Example 8 is hollow carbon,and thus is light weight. Then, it has high strength, since themesopores and the macropores, which are present in the carbon wall ofprior art hollow carbon microparticle and provoke a decrease instrength, are almost inexistent. From this, [the microcell] can be usedas a high strength, light weight filling material.

Example 9 Carbon Microballoon

An aqueous solution with 5% total concentration of hydrolyzed lignin,sodium hydroxide and sodium chloride (the proportion in mass was1:0.25:10) was spray-dried to prepare dried complex microparticles. Thiswas heat-processed under nitrogen atmosphere at 800° C. for one hour andlet to cool. Thereafter, this was washed with water and further dried toprepare carbon microballoons such as those shown in FIG. 7. Thediameters of the microparticles shown in FIG. 7 were on the order of 2to 15 μm and the bulk density was 12 g/L.

The carbon microballoon obtained in the present Example 9, is anultra-light weight hollow carbon material having an external diameter of0.2 to 50 μm, a carbon wall thickness of approximately 5 to 200 nm and abulk density of 3 to 20 g/L. From this, [the microballoon] can be usedas an ultra-light filling material.

Example 10 Carbon Nanopipe Cell

An aqueous solution with 5% total concentration of hydrolyzed lignin andsodium metasilicate (the proportion in mass was 1:3) was spray-dried toprepare dried complex microparticles. This was heat-processed undernitrogen atmosphere at 600° C. for one hour and let to cool. Thereafter,this was washed with water and further dried to prepare carbon nanopipecells such as those shown in FIG. 8 (a). The diameters of themicroparticles shown in FIG. 8 (a) were on the order of 2 to 15 μm.

From the structure shown in FIG. 8 (a), the carbon nanopipe cellsobtained in the present example can be considered as one species of thecarbon microcell obtained in Example 8. The external diameter of thiscarbon nanopipe cell was 0.2 to 50 μm, and the carbon wall thickness was0.05 to 20 μm. Then, it can be considered to be a light-weight hollowcarbon material with the carbon wall thereof having a special shapecomprising a carbon nanopipe with irregularly curved and crossingstructure, as shown in FIG. 8 (b), having an external diameter of 5 to50 nm and a carbon wall thickness of 1 to 5 nm.

The carbon nanopipe cell obtained in the present example is amicron-size carbon microparticle, and at the same time, the carbon wallhas a structure comprising a nanopipe with numerous voids, thus, thestrength is low, which can be used as specially shaped light-weightfilling materials, the particles disintegrating by mixing with a resinor rubber and being dispersed in the matrix at the nanopipe level. Inaddition, exploiting the fact that the carbon wall has a structurecomprising a nanopipe with numerous voids, it can also be used ascontrolled-release materials for substances such as agriculturalchemicals and medicinal drugs.

Example 11 Carbon Nanocell

An aqueous solution with 5% total concentration of hydrolyzed lignin andsodium orthosilicate (the proportion in mass was 1:10) was spray-driedto prepare dried complex microparticles. This was heat-processed undernitrogen atmosphere at 600° C. for one hour and let to cool. Thereafter,this was washed with water and further dried to prepare a carbonmaterial in which the carbon wall of the carbon microparticle made ofcarbon nano microparticles (referred to as “carbon nanocell”) as thoseshown in FIG. 9. The external diameter of this carbon nanocell shown inFIG. 9 was approximately 3 to 10 nm.

Since the carbon nanocell obtained in the present example has largevoids within the particle, an external diameter of 3 to 30 nm and acarbon wall thickness of 1 to 5 nm, it can be considered to be anultra-fine light-weight hollow carbon material. In addition, it has thecharacteristics of having irregular shape and being of non-graphitequality. Then, since the specific surface area is 1400 to 1600 m²/g, ithas the characteristics of being ultra-fine and having a large specificsurface area. That is to say, from the facts that the particle size iseven smaller than prior art carbon black, and furthermore, improvementof reinforcement or the like can be expected with the addition of tinyamount, it can be used as an ultra-fine light-weight filler. Inaddition, from the fact that the specific surface area is extremelylarge, it can be used as an ultra-fine highly surface adsorbingmaterial.

INDUSTRIAL APPLICABILITY

The carbon microparticles obtained by the preparation method of presentinvention being light-weight and some having an equivalent specificsurface area to commercially available activated charcoal, in additionto uses as reinforcing agent for rubber such as of a tire, they can beused as activated charcoal, controlled release material, black pigment,toner, color filter, conductive material, electrostatic preventionagent, battery electrode material, viscous fluid and the like.

1. A carbon microparticle preparation method, wherein a solution oforganic raw material having lignin as a main constituent is turned intoa micro-droplet, the micro-droplet is dried to prepare a microparticle,and the microparticle is thermally decomposed in a range of 300° C. to1200° C. to prepare a carbon microparticle.
 2. A carbon microparticlepreparation method, wherein a mixed solution of an organic raw materialhaving lignin as a main constituent and an inorganic substance is turnedinto a micro-droplet, the micro-droplet is dried to prepare amicroparticle, and the microparticle is thermally decomposed in a rangeof 300° C. to 1200° C. to prepare a carbon microparticle.
 3. The carbonmicroparticle preparation method according to claim 2, wherein theinorganic substance is a metal compound constituted by one or morespecies selected from the group consisting of an oxide, a hydroxide, acarbonate and a halide of a metal, and based on the property that acarbon wall thickness of the carbon microparticle becomes thinner as theproportion of the metal compound added increases, the proportion of themetal compound added is adjusted to control the carbon wall thickness ofthe microparticle.
 4. The carbon microparticle preparation methodaccording to claim 2, wherein prior to being taken out into the air, thecarbon microparticle obtained during the thermal decomposition or afterthe thermal decomposition is brought into contact beforehand with a gashaving low reactivity, thereby inactivating the surface of the carbonmicroparticle by reaction with the gas and inhibiting a rapid heatgeneration occurring when the carbon microparticle is taken out into theair.
 5. A carbon microparticle preparation method, wherein a mixedsolution of organic raw materials having lignin as a main constituentand a basic compound is turned into a micro-droplet, the micro-dropletis dried to prepare a microparticle, and the microparticle is thermallydecomposed in a range of 300° C. to 1200° C. and the specific surfacearea is increased to prepare a carbon microparticle.
 6. A carbonmicroparticle preparation method, wherein preprocessing to raise theconstituent ratio of lignin is carried out on a pulp waste solution, thepulp waste solution after the preprocessing is turned into amicro-droplet, the micro-droplet is dried to prepare a microparticle,and the microparticle is thermally decomposed in a range of 300° C. to1200° C. to prepare a carbon microparticle.
 7. A carbon microparticlepreparation method, wherein preprocessing to raise the constituent ratioof lignin is carried out on a pulp waste solution, a solution comprisingthe pulp waste solution after the preprocessing added with an inorganicsubstance is turned into a micro-droplet, the micro-droplet is dried toprepare a microparticle, and the microparticle is thermally decomposedin a range of 300° C. to 1200° C. to prepare a carbon microparticle. 8.The carbon microparticle preparation method according to claim 6 or 7,wherein separation-collection of high molecular weight lignin is carriedout by ultrafiltration as the preprocessing.
 9. The carbon microparticlepreparation method according to claim 6 or 7, wherein a process iscarried out as the preprocessing, in which carbon dioxide is absorbed bythe pulp waste solution to thereby decrease a hydrogen ion index anddeposit a portion of an organic constituent, and the organic constituentis separated.
 10. A hollow carbon microparticle, which is obtained byturning a solution of lignin, or lignin and an inorganic substance intoa micro-droplet, drying the micro-droplet to prepare a microparticle,and thermally decomposing the microparticle in a range of 300° C. to1200° C.
 11. A hollow carbon microparticle, which is obtained by turninga solution of lignin, or lignin and a basic compound into amicro-droplet, drying the micro-droplet to prepare a microparticle, andthermally decomposing the microparticle in a range of 300° C. to 1200°C., wherein the hollow carbon microparticle has an external diameter of0.2 to 50 μm and a carbon wall thickness of 0.05 to 20 μm.
 12. Thehollow carbon microparticle according to claim 11, which has a highspecific surface area, wherein the proportion in mass of the lignin andthe basic compound is 1:0.5 to 1:2.
 13. A hollow carbon microparticle,which is obtained by turning a solution of lignin as well as a metalcompound constituted by one or more species selected from the groupconsisting of an oxide, a hydroxide, a carbonate and a halide of a metalinto a micro-droplet, drying the micro-droplet to prepare amicroparticle, and thermally decomposing the microparticle in a range of300° C. to 1200° C., wherein the hollow carbon microparticle has anexternal diameter of 0.2 to 50 μm, a carbon wall thickness of 5 to 200nm and a bulk density of 3 to 20 g/L.
 14. The hollow carbonmicroparticle according to claim 13, wherein the proportion in mass ofthe lignin and the metal compound is 1:3 to 1:20.
 15. A hollow carbonmicroparticle, which is obtained by turning a solution of lignin andmetasilicate into a micro-droplet, drying the micro-droplet to prepare amicroparticle, and thermally decomposing the microparticle in a range of300° C. to 1200° C., wherein the hollow carbon microparticle has anexternal diameter of 0.2 to 50 μm and a carbon wall thickness of 0.05 to20 μm, and wherein the carbon wall thereof is constituted by a carbonnanopipe having an external diameter of 5 to 50 nm and a carbon wallthickness of 1 to 5 nm.
 16. The hollow carbon microparticle according toclaim 15, wherein the proportion in mass of the lignin and themetasilicate is 1:3 to 1:20.
 17. A hollow, non-graphite carbonmicroparticle, which is obtained by turning a solution of lignin andorthosilicate into a micro-droplet, drying the micro-droplet to preparea microparticle, and thermally decomposing the microparticle in a rangeof 300° C. to 1200° C., wherein the hollow, non-graphite carbonmicroparticle has an external diameter of 3 to 30 nm, a carbon wallthickness of 1 to 5 nm and a specific surface area of 1400 to 1600 m²/g.18. The hollow, non-graphite carbon microparticle according to claim 17,wherein the proportion in mass of the lignin and the orthosilicate is1:5 to 1:20.